Impact Resistant Composite Article

Abstract

An impact resistant composite article has at least two or more fibrous fabric layers and a polymeric layer disposed between at least some of the fabric layers. The peel strength measured at 20° C. between the fabric layer an adjacent polymeric layer after pressing for 30 minutes at 500 psi and 160° C. is less than 1 kg/cm, and where the weight % of polymeric resin relative to the resin plus fabric is greater than 5%.

1 . An impact resistant composite article comprising two or more fibrous fabric layers and a polymeric layer disposed between at least some of the fabric layers, in which the peel strength measured at 20° C. between the fabric layer and an adjacent polymeric layer after pressing for 20 minutes at 500 psi and 160° C. is less than 1 kg/cm, and where the weight % of polymeric resin relative to the resin plus fabric is between 8% and 15% and where the polymeric layer comprises a material selected from the group consisting of a thermoplastic material, a blend of thermoplastic materials, a thermosetting material, a blend of thermosetting materials, and mixtures thereof; and where the polymeric layer does not contain a thermoplastic material and a thermosetting material. 
     
     
         2 . The composite article of  claim 1  in which the weight % or polymeric resin relative to the resin plus fabric is between 10% and 13%. 
     
     
         3 . The composite article of  claim 1  in which the fabric layer is at least partially woven. 
     
     
         4 . The composite article of  claim 1  in which the fabric layer comprises a polymer selected form the group consisting of aramid, UHMWPE, UHMWPP, poly vinylalcohol, polyazole and combinations or blends thereof. 
     
     
         5 . The composite article of  claim 3  in which the fabric comprises poly (p-phenylene terephthalamide). 
     
     
         6 . The composite article of  claim 1  which comprises an acid ethylene copolymer disposed between at least two of the fabric layers 
     
     
         7 . The composite article of  claim 6  in which the ethylene copolymers are neutralized with an ion selected from the group consisting of sodium, potassium, lithium, silver, mercury, copper (I), beryllium, magnesium, calcium, strontium, barium, copper (II), cadmium, mercury, tin, lead, iron, cobalt, nickel, zinc, aluminum, scandium, iron, yttrium, titanium, zirconium, hafnium, vanadium, tantalum, tungsten, chromium, cerium, iron and combinations thereof. 
     
     
         8 . The composite article of  claim 1  in which the fabric is repellant coated. 
     
     
         9 . The composite article of  claim 1  in which the fabric is at least partially finished with a fluorinated material. 
     
     
         10 . The composite article of  claim 9  in which the fluorinated material is selected from the group consisting of fluorinated acrylate copolymer and a fluorinated methacrylate copolymer. 
     
     
         11 . The composite article of  claim 1  in which the polymer layer further comprises a material selected form the group consisting of a surfactant, a plasticizer, and a mixture or combination thereof. 
     
     
         12 . The composite article of  claim 11  in which the surfactant is 1-decanol. 
     
     
         13 . A panel comprising the composite article of  claim 1 . 
     
     
         14 . A helmet comprising the composite article of  claim 1 .